TOYOTA CAMRY 1999 Service Repair Manual

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±61
OVERDRIVE BRAKE INSPECTION
INSPECT DISCS, PLATES AND FLANGE
Check if the sliding surfaces of the discs, plates and
flange are worn or burnt. If necessary, replace them.
HINT:

If the lining of the disc is peeling off or discolored, or
even if a part of the printed numbers are defaced, re-
place all discs.

Before assembling new discs, soak them in ATF for
at least 15 minutes.
OVERDRIVE DIRECT CLUTCH
DISASSEMBLY
1. CHECK PISTON STROKE OF DIRECT CLUTCH
Using a dial indicator, measure the piston stroke while ap-
plying and releasing compressed air (392 ± 785 kPa, 4 ±
8 kgf/cm
2, 57± 114 psi).
Piston stroke:
1.21 ± 1.91 mm (0.0476 ± 0.0752 in.)
If the piston stroke is greater than the maximum, inspect
the each component.
2. REMOVE OVERDRIVE DIRECT CLUTCH FROM CASE
AX0FY±02
AX0FZ±02

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±62
3. REMOVE BEARING AND RACE FROM CLUTCH
DRUM AND CASE
4. REMOVE SNAP RING WITH SCREWDRIVER
5. REMOVE FLANGES, DISCS AND PLATES
6. REMOVE PISTON RETURN SPRING
(a) Place SST on the spring retainer and compress the spring
with a shop press.
SST 09350±32014 (09351±32070, 09351±32200)
(b) Remove the snap ring.
(c) Remove the piston return spring.

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±63
7. REMOVE PISTON FROM CLUTCH DRUM
(a) Install the clutch drum of the case.
(b) Apply compressed air to the pressure apply hole of the
case.
(c) Remove the piston from the clutch drum.
If the piston does not come out completely, use needle±
nose pliers to remove it.
(d) Remove the clutch drum from the case.
8. REMOVE O±RINGS
Remove the 2 O±rings from the piston.
OVERDRIVE DIRECT CLUTCH INSPECTION
1. INSPECT OVERDRIVE DIRECT CLUTCH
(a) Check that the check ball is free by shaking the piston.
(b) Check that the valve does not leak by applying lowpres-
sure compressed air.
2. INSPECT DISCS, PLATES AND FLANGES
Check that the sliding surfaces of discs, plates and
flanges are worn or burnt. If necessary, replace them.
HINT:

If the lining of the disc is peeling off or discolored, or
even if a part of the printed numbers are defaced, re-
place all discs.

Before assembling new discs, soak them in ATF for
at least 15 minutes.
3. CHECK DIRECT CLUTCH BUSHING
Using a dial indicator, measure the inside diameter of the
two direct clutch bushings.
Maximum inside diameter:
22.09 mm (0.8697 in.)
If the inside diameter is greater than the maximum, re-
place the direct clutch drum.
AX0G0±02

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±64
OVERDRIVE DIRECT CLUTCH ASSEMBLY
1. INSTALL CLUTCH PISTON
(a) Install new O±rings to the piston. Coat the O±rings with
AT F.
(b) Press the piston into the drum with the cup side up, being
careful not to damage the O±ring.
2. INSTALL PISTON RETURN SPRING
(a) Install the return spring and set snap ring in place.
(b) Place SST on the spring retainer, and compress the
spring with a shop press.
SST 09350±32014 (09351±32070, 09351±32200)
(c) Install the snap ring with a screwdriver. Be sure end gap
of snap ring is aligned with the groove of the clutch drum.
3. INSTALL PLATES, DISCS AND FLANGE
Install in order: P=Plate D=Disc
Flange ± D ± P ± D ± Flange
AX0G1±02

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±65
4. INSTALL SNAP RING
Be sure end gap of the snap ring is not aligned with the
groove of the clutch drum.
5. INSTALL BEARING AND RACE
(a) Coat the bearing with petroleum jelly and install it facing
the race side downward to the clutch drum.
Bearing:
Outer diameter
46.3 mm (1.823 in.)
Inner diameter
26.2 mm (1.031 in.)
(b) Coat the race with petroleum jelly and install it to thecase.
Race:
Outer diameter
43.0 mm (1.693 in.)
Inner diameter
24.5 mm (0.965 in.)
6. INSTALL DIRECT CLUTCH ON CASE
7. RECHECK PISTON STROKE OF DIRECT CLUTCH
Using a dial indicator, measure the piston stroke while ap-
plying and releasing compressed air (392 ± 785 kPa, 4 ±
8 kgf/cm
2, 57± 114 psi).
Piston stroke:
1.21 ± 1.91 mm (0.0476 ± 0.0752 in.)

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±66
COUNTER DRIVE GEAR DISASSEMBLY
1. CHECK OPERATION OF ONE±WAY CLUTCH
(a) While turning the overdrive gear clockwise, install the ov-
erdrive direct clutch into the one±way clutch.
(b) Hold the overdrive direct clutch and turn the intermediate
shaft. The shaft should turn freely clockwise and should
lock counterclockwise.
(c) Remove the overdrive direct clutch.
2. CHECK COUNTER DRIVE GEAR PRELOAD
(a) Hold the intermediate shaft in a vise with soft jaws.
(b) Using a tension gauge, measure the preload.
Preload (at starting):
9 ± 15 N (920 ± 1,530 gf, 2.0 ± 3.4 lbf)
HINT: Turn the counter drive gear right and left several
times before measuring the preload.
3. REMOVE RETAINING PLATE
(a) Remove the snap ring with a screwdriver.
(b) Remove the retaining plate.
4. REMOVE ONE±WAY CLUTCH AND OUTER RACE
AX0G2±02

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±67
5. REMOVE NO.3 OVERDRIVE PLANETARY THRUST
WASHER
6. REMOVE ONE±WAY CLUTCH FROM OUTER RACE
Note the direction of the one±way clutch.
7. REMOVE PLUGS FROM PLANETARY GEAR
Remove the 4 plugs with a magnetic finger.
HINT: Be careful not to lose them.
8. REMOVE ADJUSTING NUT AND WASHER
(a) Pry off the locking washer with chisel.
(b) Using SST, loosen the adjusting nut.
SST 09350±32014 (09351±32080)
(c) Remove the adjusting nut and washer.

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±68
9. REMOVE INTERMEDIATE SHAFT BEARING
Using SST, press out the bearing from the shaft.
SST 09950±00020
10. REMOVE COUNTER DRIVE GEAR AND FRONT
BEARING
Press out the gear and bearing together.
11. REMOVE REAR BEARING
Using SST, press out the bearing.
SST 09950±00020
12. REMOVE OVERDRIVE PLANETARY RING GEAR
FROM COUNTER DRIVEGEAR
(a) While pulling up the ring gear, compress the snap ring
with needle±nose pliers and remove it from the groove.
(b) Remove the ring gear from the counter drive gear.
13. REMOVE OUTER RACES FROM COUNTER DRIVE
GEAR
Drive out the 2 races with a brass bar and hammer.

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±69
14. REMOVE SNAP RING FROM COUNTER DRIVE GEAR
Using a screwdriver, remove the snap ring.
OVERDRIVE PLANETARY GEAR
INSPECTION
MEASURE PLANETARY PINION GEAR THRUST
CLEARANCE
Using a feeler gauge, measure the planetary pinion gear
thrust clearance.
Standard clearance:
0.20 ± 0.50 mm (0.0079 ± 0.0197 in.)
COUNTER DRIVE GEAR ASSEMBLY
1. INSTALL SNAP RING INTO COUNTER GEAR
Install the snap ring with a screwdriver.
2. INSTALL OUTER RACES INTO COUNTER DRIVE
GEAR
Using SST, press in the 2 outer races to the gear both
side.
SST 09350±32014 (09351±32120, 09351±32150)
HINT: Press in the 2 outer races until they touch the snap
ring. Tap the races in straight, so that they do not tilt.
3. INSTALL OVERDRIVE PLANETARY RING GEAR INTO
COUNTER DRIVEGEAR
While pushing down the ring gear, squeeze the snap ring
end with a needle±nose pliers, and install it into the
groove.
HINT: When the snap ring is fully seated, the end will be
free.
AX0G3±02
AX0GU±02

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±70
4. INSTALL REAR BEARING
Using SST, press in the bearing onto the shaft.
SST 09350±32014 (09351±32120)
HINT: Press in the bearing until the side surface of the in-
ner race touches the shaft.
5. INSTALL COUNTER DRIVE GEAR AND FRONT BEAR-
ING
(a) Install the gear onto the shaft, and mesh the ring gear with
the planetary pinions.
(b) Place the front bearing onto the shaft.
HINT: Hold the ring gear to prevent it from falling.
(c) Using SST, press in the bearing until there is slight play
between the bearings.
SST 09350±32014 (09351±32120)
6. INSTALL INTERMEDIATE SHAFT BEARING
Using SST, press in the bearing until it slightly touches the
front bearing of the counter drive gear.
SST 09350±32014 (09351±32120)
HINT: The counter drive gear can be turned lightly.
7. PLACE NEW LOCKING WASHER AND ADJUSTING
NUT ONTO INTERMEDIATE SHAFT